Process for molding a cloth in a hot mold and molding a cloth covered foam filled product

ABSTRACT

A method of molding cloth. A special multi-layer cloth is first preheated and then drawn into a heated mold by means of a vacuum between the cloth and the mold. The cloth includes a fabric layer having a heat-fixable fiber, a polyurethane foam layer and a polyvinyl chloride film layer bonded together. The cloth is preheated to at least the greater of the set temperatures of the fabric layer and the polyvinyl chloride film. The mold is heated to at least the same temperature. After the cloth has conformed to the contours of the mold, the cloth is cooled in the mold. The steps of heating the cloth in the mold and then cooling the cloth sets the stitch of the fabric to the contours of the mold. Polyurethane foam may then be poured into the mold and allowed to expand to form a seat cushion or the like.

BACKGROUND OF THE INVENTION

This invention relates to a method of molding cloth, and moreparticularly, to a method of molding a multi-layer, vacuum-formablecloth which may be employed as the outer covering of seat cushions,acoustical dividers and the like.

The traditional method of making upholstered seat cushions involves: (1)cutting the cover material according to an appropriate pattern; (2)sewing the cut material; and (3) stuffing the cushion. High labor costsresult, since, in many situations, the cutting and sewing operations areextensive and much must be performed by hand.

To reduce the cost of manufacturing seat cushions, a molding process wasdevised for manufacturing seat cushions comprising a foam portion havingan integral vinyl cover. The vinyl covering is first heated and thendrawn into a cold mold by means of a vacuum between the vinyl and themold. As the vinyl cools, it assumes the contours of the mold. Foam isthen poured into the mold to form the integral foam portion of the seatcushion. This process significantly reduces manufacturing costs andresults in a superior seat.

However, cloth has many advantages over vinyl. Specifically, cloth iswater vapor permeable. Perspiration that normally collects behind aperson sitting in a vinyl seat can pass through cloth and be evaporatedso that cloth feels cooler during warm weather and warmer during coldweather. Furthermore, the feel of the cloth, the "hand", is much moreluxurious and elegant.

To reduce the expense of cloth covered seats, attempts have been made todevelop cloth molding processes similar to that described above withrespect to vinyl. U.S. Pat. No. 3,954,537 to Alfter et al discloses aprocess for producing multi-layer sheets having a polyurethane foamlayer bonded to a cross-linked polyethylene foam layer. After disclosesthat it is particularly advantageous to join the foam layers withfurther layers such as fabric to form upholstery components. Alfterrelies on the strength of the bond between the polyurethane foam andpolyethylene foam to accomplish the molding. However, polyurethane foamin an uncured state can easily change shape. Since Alfter relies on thebonding of two foam layers, and not on the setting in some manner of theouter fabric layer, intricate detail is most likely not possible, andsince polyurethane foam in an uncured state can change shape easily, itappears likely that the fabric layer would tend to return to its flatshape.

German Offenlegungsschrift No. 2,227,143 to Bayer AG, discloses a seatcushion with a textile cover and foam core. A fabric is bonded to apolyether-urethane foam layer which in turn is bonded to a film sealinglayer. This multi-layer fabric is first heated to 70° C. (158° F.) andthen drawn into a mold. A soft foam is then poured into the mold to forma seat cushion.

The following patents describe methods of forming a multi-layer clothsimilar to that described above:

U.S. Pat. No. 3,941,633-Wang et al (1976)

U.S. Pat. No. 3,933,548-Anderson et al (1976)

U.S. Pat. No. 3,748,217-May et al (1973)

British Pat. No. 1,227,760-Dunlop (1971).

Although the cloth molding processes described in Bayer and Alfter dowork with some molds and fabrics, the applications are rather limited.For example, the Bayer Patent recites that only elastic knit fabrics maybe employed. The complexity of the mold pattern is also significantlylimited. In the Bayer and Alfter processes, the molded fabric will notretain the contours of more intricate or sharp mold features.

One of the problems with the prior art procedures is that the stitch ofthe fabric layer is not set in the shape of the mold. Therefore, thefabric layer tends to pull against the other cloth layers or theunderlying foam core. Over time details of the mold will tend toflatten.

SUMMARY OF THE INVENTION

It is particularly advantageous to set the stitch of the fabric layer inthe mold. This is accomplished by employing a mold heated to at leastthe fabric set temperature when the cloth is drawn into the mold. Themold is then allowed to cool with the fabric conforming to the shapethereof. By this process the fabric stitch is set to the precisecontours of the mold.

In this invention a cloth having a fabric layer bonded to an elastic,preferably thermoplastic, composition layer is drawn into the mold by avacuum between the cloth and the mold. The mold is heated to atemperature sufficient to set the stitch of the fabric. The mold andcloth are then allowed to cool (also at part of the setting process)after which foam is poured into the mold. The other portion of the moldis positioned and the poured-in-place foam is permitted to expand. Afinished seat cushion is then extracted from the mold.

Since the mold is heated to the stitch setting temperature and since thecloth is cooled in the mold, the fabric stitch is heat set to the shapeof the mold. Therefore, the fabric layer works together with theunderlying elastic composition layer so that the cloth or cushionmaintains the shape of the mold after removal. In addition, since themold is hot, and the cloth is pressed against the mold with a fairamount of pressure, the molding process tends to finish the cloth.

The use of cloth, and particularly the cloth molding process of thepresent invention, results in numerous advantages. Cushion shapes thathad heretofore been impossible, particularly is sewn construction, areeasily obtained by the process of the present invention. The possibleshapes include comlex curves, concave and convex portions, tufts, andthe simulation of tufting buttons. Many of these shapes have not evenbeen possible with previous cloth molding processes.

Labor savings are achieved with the cloth molding process of the presentinvention, because the cloth is processed and shaped much more quicklythan in the traditional cutting and sewing process. Shapes commonlyfound in tufted furniture require yards of sewing. The assembly of tuftsand tufting buttons also require extensive labor. With the presentinvention, they can be vacuum formed instantaneously, complete withsimulated tufting buttons and poured-in-place foam.

The present invention makes possible the exact duplication of shapes.The inaccuracies of sewn construction are eliminated.

The integrity of the cloth is improved by this process since the clothis held in place by a sandwich construction, thus eliminating thecreasing or puckering of material which occurs in upholstered furnitureafter use.

The durability of the resulting cushion is improved because the clothcomposite and the polyurethane poured-in-place foam act as a unit. Thisimproves the life of the cover, because it flexes with the foam ratherthan independent of it.

The present invention may be employed to mold cloth for any conceivableapplication. Such applications include automotive vehicle seats,aviation seats, and dental chair cushions, drafting stool cushions,other seating applications; padding for headboards, baby carriages, barfronts, church kneelers, boots, school buses, and hand rails; andpaneling and wall coverings for elevators, offices, tables, and kitchencabinets.

BRIEF DESCRIPTION OF THE DRAWING

These and other objects and advantages of the invention will become moreapparent and more readily appreciated from the following detaileddescription of the presently preferred exemplary embodiment of theinvention taken in conjunction with the accompanying drawing, of which:

FIG. 1 is a cross section of the product of the present invention;

FIG. 2 is an illustration of the preheating step of the presentinvention;

FIG. 3 is an illustration of the cloth insertion step of the presentinvention;

FIG. 4 is an illustration of the heating step of the present invention;

FIG. 5 is an illustration of the foam pouring step of the presentinvention;

FIG. 6 is an illustration of the curing step of the present invention;

FIG. 7 is an illustration of the cushion extraction step of the presentinvention; and

FIG. 8 is an illustration of the resulting product of the presentinvention.

DESCRIPTION OF THE PREFERRED EMBODIMENT I. The Cloth

An important aspect of the present invention is the particular type ofcloth which is employed. Referring now to FIG. 1, cloth 10 includesfabric layer 12 bonded to elastic composition layer 4. Fabric layer 12is the exterior, decorative layer which enhances the appearance of theproduct resulting from the present invention. Also, the use of fabricenhances the thermal comfort of the product due to the air-flow throughthe fabric.

A. Fabric Layer

Fabric layer 12 may be either knitted or woven. Knitted fabrics may beeither warp knit or circular knit, single knit or double knit. Nearlyany natural, artificial or synthetic material may be employed such aswool, cotton, polyamide, polyester, vinyl chloride, vinyl chlorideacrylonitrile (modacrylic) or polyacryl fibers.

Molding intricate patterns is more easily accomplished with fabricshaving greater stretch. Therefore, the process is more easily performedwith knitted materials than woven materials since knitting produces amore elastic fabric than weaving. Polyamide, such as type 6 and type6.6, polyester, vinyl chloride, vinyl chloride acrylonitrile copolymers,elastomer urethane and polyacryl fibers are preferable materials forweaving due to their inherent elasticity. Furthermore, the use as aground yarn of the fabric of any of the texturized polyamide orpolyester high elasticity yarns, or very high thermoplastic yarns likevinyl chloride and vinyl chloride acrylonitrile aids the moldingprocess.

Some fabrics are more easily heat set than others. For example,polyamide, polyester, vinyl chloride, vinyl chloride acrylonitrile aremore easily heat set than cotton and wool.

To maintain the maximum amount of elasticity in a fabric, it ispreferred that the fabric stitch have never have been thermally set. Thesignificance and details of this aspect of molding cloth is fullydisclosed in two U.S. applications one to James F. Lischer Ser. No.22,593 and the other to James F. Lischer and Raoul Quertain, Ser. No.22,591 both entitled PROCESS FOR MOLDING CLOTH INCLUDING A FABRIC LAYER,THE STITCHES THEREOF HAVING NEVER BEEN THERMALLY SET, and both filedconcurrently and assigned commonly herewith, the contents of which areincorporated herein by reference. Many of the fabric finishing steps,such as tentering, calendering and shrinkage control heat the fabric,thus setting the stitch. The concept of setting the stitch is well knownin the art and is easily measured by comparing the degree of elasticityof a fabric immediately after weaving or knitting, and again afterfinishing. If the fabric has become heat set during the finishingprocess, the elasticity is greatly reduced. Clearly, employing heat todry a fabric (as occurs in the tentering, calendering and shrinkagecontrol processes) sets the fabric stitch. Tensioning the fabric whileit is heated increases the degree to which the stitch is set.

In addition to many of the fabric finishing steps, some dyeing processesmust be avoided. In many dyeing procedures the cloth is sewn into a ropeand processed under tension. It is common to heat the dye bath toapproximately the boiling point of water. The material is then dried ata raised temperature. This may heat set the fabric stitch. It has beenfound that yarn dyeing avoids this problem since the weaving or knittingprocess creates elasticity in the fabric. It appears that the realproblem to be avoided is setting the stitch of the fabric rather thanheat setting, in some manner, the yarns from which the fabric iscreated.

The temperature to which a fabric may be heated before the stitchbecomes set varies with the type of fabric. For example, the stitch of apolyamide fabric may become set at a temperature of 93° C. (200° F.).With some fabrics, particularly the more elastic ones, normal finishingmay be employed since sufficient stretch remains in the fabric afterfinishing.

B. Foam Layer

In the preferred embodiment, elastic composition layer 14 includes foamlayer 16 and film layer 18. Foam layer 16 must have good adhesion toboth fabric 12 and film 18. Foam layer 16 is preferably any typical openmicrocell soft foam. The preferred embodiment employs polyester-typepolyurethane foam, although other foams are suitable, such aspolyester-polyether-type polyurethane. An advantage of polyester-typepolyurethane foam over polyether-type polyurethane is that it has abetter "memory". Polyester-type foam tends to retain the shape in whichit was molded better than polyether-type polyurethane foam.

Foam layer 16 allows movement of fabric 12 relative to film 18 andprevents the rupture of film 18 that might result from elongation ofcloth 10 if fabric 12 were directly attached to film 18. Obviously, ifan alternative method is employed to prevent rupturing, foam layer 16would not be necessary.

Foam layer 16 also improves the "hand" or feel of cloth 10. Since foam16 is preferably open celled, air may circulate through the foam thusimproving the thermal comfort of the seat. Neoprene foam may also beused; however, it is less desirable since it is a closed cell foam.

In the preferred embodiment, foam 16 is 1.5-6 millimeters (mm) thick andhas a density of 30-60 Kg/m³. Also, foam 16 should stretch 300-400%before breaking. As the density of the foam increases, the degree towhich the foam will stretch before breaking increases.

The appropriate thickness of the foam should be determined by theparticular application. The foam must not be so thick as to causeintricate patterns in a design to spring back after removal from themold. On the other hand, a thicker foam layer enhances the hand and airpermeability of the cloth.

C. Film Layer

Film layer 18 may be any elastic, preferably heat-fixable, film whichcan adhere to both foam layer 16 and poured-in-place foam 20. Film 18 ispreferably 0.03-0.7 mm thick and is able to withstand a 400% surfacedeformation. For the invention to work properly, the stretch limits ofelastic composition layer 14 must be approximately equal to or exceedingthe stretch limits of fabric 12.

The film should have a reasonably long life, must resist dry cleaningsolvent, and not be affected by water, humidity or oxidizing agents.

One purpose of the film 18 is to guarantee that the cloth is air tightso that it may be drawn into the mold by a vacuum. Another purpose is toprevent poured-in-place foam 20 from penetrating through fabric 12, thusruining the aesthetic value of the product. Furthermore, the film mustresist the chemical products in the poured-in-place foam.

In the preferred embodiment, film 18 is polyvinyl chloride film. Thisfilm is closed cellular, and is well suited because it is athermoplastic material. However, it hardens when plasticizers in thefilm migrate. Newly developed polymeric plasticizers may be employed toovercome the migration problem. If polyvinyl chloride is utilized asfilm 18, the thickness is preferably 0.1-0.3 mm.

The polyvinyl chloride film of the preferred embodiment has thefollowing composition (% by weight of total):

    ______________________________________                                        Vinyl Chloride      50.0-55.0                                                 Phosphate/phtalate plasticizers                                                                   35.0-40.0                                                 Light and heat stabilizers                                                                        2.0                                                       Epoxy               0.5                                                       Fillers/pigments    7.5                                                       ______________________________________                                    

If polyvinyl chloride is employed as film 18, it is preferable that itbe coated on both sides with polyester-type polyurethane film. FIG. 1illustrates polyvinyl chloride layer 22 coated on both sides withpolyurethane film layers 24 and 26. Film layer 24 is preferably about 20microns thick, while film layer 26 is preferably about 6 microns thick.Polyurethane film layers 24 and 25 permit bonding of polyvinyl chloridelayer 22 to poured-in-place foam 20. Polyurethane coatings 24 and 26also help stop the migration of plasticizers in polyvinyl chloride film22.

Polyester-type polyurethane film may also be employed as film layer 18.This film is highly deformable with a poor memory under heat, because itis thermoplastic. These characteristics are obviously advantageous inthe molding process of the present invention. It appears that athickness of 0.2-0.6 mm is preferred. Another advantage of this film isthat it is water vapor permeable, enhancing the thermal comfort of thefinished product.

The major problem with this film is that pin holes tend to develop fromgas bubbles created during manufacturing. This would permitpoured-in-place foam 20 to penetrate through fabric 12. To avoid thisproblem, the film must be cured very slowly. Otherwise, the bubblesburst during molding to create pin holes.

Rubber may also be employed as film 18. The rubber must be unvulcanizedand may be either naturel or synthetic. The same type of rubber productthat is used in bed sheeting is ideal.

The major problem with rubber film is its odor. Anti-oxidizing agentsmust be used. However, care must be exercised in choosing theanti-oxidizing agents since many of the agents commonly used wouldmigrate to the adjacent foam layers over approximately one year anddistort the foam. However, non-migrating oxidizing agents are wellknown. Blocking agents can be placed in the rubber that would break downat a predetermined temperature allowing the rubber to set or vulcanizeduring the molding process. When the rubber is vulcanized during themolding process, the rubber will hold the shape of the mold quite wellafterwards.

Ethylene vinyl acetate copolymer (EVA) may also be employed as film 18.This film is an elastomer and exhibits good stretch and poor memory athigher temperatures. However, EVA is sensitive to high temperatures. Atabout 150° C. it begins to melt and form pin holes. EVA is weak inresisting abrasion. Pin holes form readily from handling. The film maybe made by a rubber calendering system with which large quantities canbe easily produced.

A number of other films may also be used such as neoprene film.

D. Bonding The Layers

The bonding of the various layers within elastic composition layer 14and the bonding of elastic composition layer 14 to fabric 12 must becarefully performed to avoid delamination. Polyvinyl chloride film 22and polyurethane elastomer films 24 and 26 may be applied to foaminterlayer 16 by a transfer process, well known in the art.Specifically, each film is applied as a liquid, the thickness beingcontrolled by a blade. The film is then heated to jellificationtemperature by infra-red lamps. A second controlled thickness is appliedand heated after polyurethane foam 16 is applied, the films pass throughcalender rollers at room temperature, after which the film is bakedunder infra-red lamps. If unvulcanized rubber is employed as film 18, itis passed between calender rollers heated to a temperature less than thevulcanizing temperature.

After film layer 18 is joined to one side of foam layer 16 to formelastic composition layer 14, the opposite side of foam 16 is heated, asin a Reeves machine, and the fabric material is flame-bonded thereto. Itis not preferable to join both fabric 12 and film 18 to foam 16 byflame-bonding, as this will result in a greater tendency fordelamination of film layer 18.

If foam layer 16 is eliminated, film layer 18 may be glued directly tofabric 12 using, for example, acrylic glue. When film 18 is applied tofoam layer 16, the foam must be relaxed and not under tension.

II. Molding Process

Cloth 10, as described above and illustrated in FIG. 1, is ideallysuited for molding. Cloth 10 is first cut to size and, as illustrated inFIG. 2, preheated to a temperature greater than the temperature at whichfabric layer 12 is heat set and film layer 18 loses its memory. Eitherradiant heat or heated air may be employed. With polyvinyl chloride asfilm 18, polyurethane as foam 16 and either wool, polyester or polyamideas fabric 12, a temperature of between 138° C. (280° F.) and 160° C.(320° F.) has been found ideal.

After preheating, hot cloth 10 is inserted in female mold portion 28 asillustrated in FIG. 3. A hollow chamber lies directly beneath the outercontours of mold 28 to which the cloth must conform. Pin holes passthrough the outer contours so that the chamber communicates with theoutside environment. A vacuum is applied to the chamber, thus drawingcloth 10 placed over mold 28 onto the outer contours, as illustrated inFIG. 4. To insure that cloth 10 does perfectly conform to the contoursof mold 28, more pin holes must be located near sharply varying contoursof mold 28 than in the more flat portions of mold 28.

Cloth 10 must be heat set in mold 28 to maximize its ability to retainits shape after the molding process. To this end, mold 28 must be heatedto the heat set temperature when cloth 10 is drawn therein. Atemperature of 149° C.-182° C. (300°-360° F.) has been foundadvantageous in the preferred embodiment. Also mold 28, together withcloth 10, must be allowed to cool so that the temperature of cloth 10drops 17°-27° C. (30°-50° F.) to finish the setting process. After thetemperature of cloth 10 has been raised to 160° C. and then cooled 20°C., the stitch in fabric 12 is set in the shape of mold 28, andtherefore, cloth 10 is less likely to lose its shape after it is removedfrom the mold. Also, since cloth 10 is pressed against the mold wallswhile it is heated, the molding process finishes fabric 12.

Foam 20 may then be poured into mold 28 in its liquid state. In thepreferred embodiment, cold cure, polyether-type polyurethane foam isemployed, although any foam that adheres to film layer 18 may be used.Since a cold cure foam is used in the preferred embodiment, eitherfemale mold 28 must be cooled to a temperature below 38° C. (about 100°F.), or cloth 10 must be transferred to a cool female mold.

Male mold portion 32 is then placed over female portion 28 asillustrated in FIG. 6. After approximately 15 minutes foam 20 has fullyexpanded within the mold. The finished product may then be extractedfrom female mold portion 28 as illustrated in FIG. 7. Thereafter, thecells of poured-in-place foam 20 may be broken by pressure applied byrollers, paddles, or the like. This increases the resiliency of theproduct, prevents shrinkage due to the contraction of gas within thecells upon cooling and facilitates the circulation of air within a seatto improve the thermal comfort thereof. The result is a finished seatcushion, or the like, as illustrated in FIG. 8.

As indicated above, the ease of molding cloth 10 depends largely on thematerial used as fabric 12 and the intricacy of mold 28. With theprocess described above, relatively inelastic fabrics and complex moldsmay be employed. Specifically, the use of the process of the presentinvention enables cloth to be molded that has never been successfullymolded before. Also, the present invention permits the use of molds ofgreater complexity than has ever been successfully used. In fact, theprocess is so effective that the preheating step may be eliminated ifthe mold pattern is relatively simple or an elastic fabric, such asthose having a base of texturized polyamide or polyester, is employed.In addition, if a simple mold is employed or the fabric is elastic, thefabric may be finished in the typical fashion.

The following specific examples will serve to illustrate the clothmolding process of this invention. In all examples, fabric 12 was notsubjected, during production, to a temperature high enough to set thestitch of the fabric. Therefore, in all examples, the final heat-fixingof fabric 12 occurs in the mold.

EXAMPLE 1

A moldable cloth was prepared by flamebonding a double knit polyamidefabric to an elastic composition substrate. The fabric was made oftexturized stretch yarn that had been piece dyed after knitting. Theelastic composition substrate included an open cell polyester-typepolyurethane foam layer which had been cast or laid on a polyvinylchloride film layer. The foam had between 90 and 100 pores per cubicinch, a density of 33 Kg/m³ and a tensile strength of 300% elongationbefore breaking. The thickness of the foam was 3 mm. The film had athickness of 0.3 mm and the following composition (% by weight):

    ______________________________________                                        Vinyl chloride       50.0-55.0                                                Phosphate/phthalate plasticizers                                                                   35.0-40.0                                                Light/heat stabilizers                                                                             2.0                                                      Epoxy                0.5                                                      Fillers/pigments     7.5                                                      ______________________________________                                    

On either side of the polyvinyl chloride layer was a layer ofhydrolytically stable urethane to improve the adhesion between thepoured-in-place polyurethane foam and the polyvinyl chloride. Thethickness of the urethane film between the fabric and the polyvinylchloride was 20 microns, and the thickness of the film between thepolyvinyl chloride and the poured-in-place polyurethane foam was 6microns.

A seat cushion was made, employing this cloth, by first cutting thecloth to the required size, placing it in a frame, and heating it withradiant heat to a temperature of 160° C. (320° F.). While the cloth wasstill hot, it was drawn into the female portion of a mold by means of avacuum between the mold and the cloth. The cloth readily conformed tothe contours of the mold. The mold had been heated to a temperature of171° C. (340° F.). The heat of the cloth in the mold was sufficient toset the stitch of the fabric, and set the film. The mold, together withthe cloth, was permitted to cool 40° F. (22° C.) to set the cloth. Theplacing of the hot cloth in the hot mold, followed by the cooling stepwas sufficient to set the stitch of the fabric, and set the elasticcomposition layer to the shape of the mold.

The cloth was then transferred to a female mold heated to 37° C. (99°F.). A polyethertype polyurethane foam with a density of 52 Kg/m³ wasthen poured-in-place. The male portion of the mold was placed over thefemale portion and the foam was permitted to expand for fifteen minutes.The product was then removed from the mold. Thereafter, the pouredpolyurethane cells were broken by pressure, and the product, a molded,poured-in-place cushion, was complete.

EXAMPLE 2

A moldable cloth was prepared in the same manner as in Example 1 exceptthat the fabric was yarn dyed. The polyurethane foam of the elasticcomposition substrate had a density of 35 Kg/m³ and a thickness of 1.5mm. Also, the thickness of the polyvinyl chloride film was 0.15 mm.

A seat cushion was made employing this cloth by cutting the cloth tosize, placing the cloth in a frame and heating it by radiant heat to atemperature of 149° C. (300° F.). The heated cloth was then drawn intothe female portion of a mold preheated to a temperature of 166° C. (330°F.) under vacuum. The cloth readily conformed to the contours of themold. The mold, together with the cloth, was allowed to cool 17° C. (30°F.). The placing of the hot cloth in the hot mold, followed by thecooling step was sufficient to set the stitch of the fabric, and set theelastic composition layer to the shape of the mold.

The cloth was then transferred to a female mold heated to 38° C. (100°F.). A polyethertype polyurethane foam, with a density of 52 Kg/m³ wasthen poured-in-place. The male portion of the mold was fitted over thefemale portion and the foam was allowed to expand within the mold forfifteen minutes. After removal of the product, the cells of thepoured-in-place polyurethane foam were broken by pressure, and theproduct, a molded, poured-in-place seat cushion was complete.

EXAMPLE 3

A moldable cloth was prepared in the same manner as Example 1 except forthe following differences. A yarn dyed double knit fabric having apolyamide base and a wool face was employed. The density of thepolyurethane foam layer of the elastic composition substrate was 30Kg/m³. The thickness of the polyvinyl chloride film was 0.2 mm.

The procedure of Example 1 was employed to form a seat cushion from thecloth, except for the following differences. The cloth was preheated byradiant heat to a temperature of 157° C. (315° F.). The female portionof the mold had been preheated to a temperature of 160° C. (320° F.).After the cloth was set, it was transferred to a female mold heated to38° C. (100° F.).

EXAMPLE 4

A moldable cloth was prepared as in Example 2 except for the followingdifferences. A double knit polyamide and polyester combination fabricwas employed. The density of the polyurethane foam layer of the elasticcomposition layer was 30 Kg/m³. The thickness of the polyvinyl chloridefilm was 0.25 mm.

The cloth was employed in the process of Example 2 for making a seatcushion except for the following differences. The female mold waspreheated to a temperature of 171° C. (340° F.). After the cloth wasplaced in the heated mold, the mold, together with the cloth was allowedto drop 19° C. (35° F.). The cloth was then transferred to a female moldheated to 37° C. (98° F.).

EXAMPLE 5

A moldable cloth was prepared in a manner similar to Example 3, exceptfor the following differences. A piece dyed, single knit polyamidefabric was employed. The thickness of the polyurethane foam layer of theelastic composition substrate was 0.15 mm.

This cloth was utilized to mold a seat cushion in a manner similar tothat of Example 3 except for the following differences. The cloth waspreheated to a temperature of 149° C. (300° F.). The mold was preheatedto a temperature of 168° C. (335° F.). After the cloth was drawn intothe mold, the mold, together with the cloth was permitted to cool 17° C.(30° F.).

Although only a few exemplary embodiments of this invention have beendescribed in detail above, those skilled in the art will readilyappreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. For example, the cloth may be drawn intothe male portion of the mold.

Accordingly, all such modifications are intended to be included withinthe scope of this invention as defined in the following claims.

What is claimed is:
 1. A process for molding cloth comprising the stepsof:drawing the cloth into a heated mold, the cloth including a fabriclayer having a heat-fixable fiber, and an elastic composition layerbonded to the fabric layer, the temperature of the mold being at leastthe heat-fixable fiber set temperature; heating the cloth to at leastthe heat-fixable fiber set temperature, including the step oftransferring energy from the heated mold to the cloth; and cooling thecloth, the process heat-fixing the heat-fixable fiber of the cloth tothe shape of the mold.
 2. A process for molding cloth comprising thesteps of:drawing the cloth into a heated mold, the cloth including afabric layer having a heat-fixable fiber, and an elastic compositionlayer bonded to the fabric layer, the elastic composition layerincluding a thermoplastic film layer, the temperature of the mold beingat least the greater of the set temperature of the heat-fixable fiberand the softening temperature of the film layer; heating the cloth to atleast the greater of the set temperature of the heat-fixable fiber andthe softening temperature of the film layer, including the step oftransferring energy from the heated mold to the cloth; and cooling thecloth, the process heat-fixing the heat-fixable fiber and the film layerto the shape of the mold.
 3. A process for molding cloth comprising thestep of:drawing the cloth into a heated mold, the cloth including afabric layer having a heat-fixable fiber, and an elastic compositionlayer bonded to the fabric layer, the elastic composition including aflexible foam layer and a thermoplastic film layer, the temperature ofthe mold being at least the greater of the set temperature of theheat-fixable fiber and the softening temperature of the film layer;heating the cloth to at least the greater of the set temperature of theheat-fixable fiber and the softening temperature of the film layer,including the step of transferring energy from the heated mold to thecloth; and cooling the cloth, the process heat-fixing the heat-fixablefiber and the film layer to the shape of the mold.
 4. A process as inclaim 1, 2 or 3 further comprising the step of preheating the clothprior to the drawing step.
 5. A process for molding cloth comprising thesteps of:preheating the cloth, the cloth including a fabric layer havinga heat-fixable fiber, and an elastic composition layer bonded to thefabric layer, the temperature to which the cloth is preheated being atleast the heat-fixable fiber set temperature; drawing the cloth into aheated mold, the temperature of the mold being at least the heat-fixablefiber set temperature; heating the cloth to at least the heat-fixablefiber set temperature, including the step of transferring energy fromthe heated mold to the cloth; and cooling the cloth, the processheat-fixing the heat-fixable fiber of the cloth to the shape of themold.
 6. The process for molding cloth comprising the stepsof:preheating the cloth, the cloth including a fabric layer having aheat-fixable fiber, and an elastic composition layer bonded to thefabric layer, the elastic composition layer including a thermoplasticfilm layer, the temperature to which the cloth is preheated being atleast the greater of the set temperature of the heated-fixable fiber andthe softening temperature of the film layer; drawing the cloth into aheated mold, the temperature of the mold being at least the greater ofthe set temperature of the heat-fixable fiber and the softeningtemperature of the film layer; heating the cloth to at least the greaterof the set temperature of the heat-fixable fiber and the softeningtemperature of the film layer, including the step of transferring energyfrom the heated mold to the cloth; and cooling the cloth, the processheat-fixing the heat-fixable fiber and the film layer to the shape ofthe mold.
 7. A process for forming a cloth-covered item comprising thesteps of:preheating the cloth, the cloth including a fabric layer havinga heat-fixable fiber, and an elastic composition layer bonded to thefabric layer, the temperature to which the cloth is preheated being atleast the heat-fixable fiber set temperature; drawing the cloth into aheated mold, the temperature of the mold being at least the heat-fixablefiber set temperature; heating the cloth to at least the heat-fixablefiber set temperature, including the step of transferring energy fromthe heated mold to the cloth; cooling the cloth; and pouring foam intothe mold, the process heat-fixing the heat-fixable fiber of the cloth tothe shape of the mold and filling the back side of the molded cloth withfoam.
 8. A process as in claim 1, 5 or 7 wherein the elastic compositionlayer has a low elastic recovery after molding to facilitate theretention of the molded shape of the cloth.
 9. The process as in claim1, 2, 5 or 7 wherein the elastic composition layer includes a flexiblefoam layer formed of a polymer selected from the group consisting ofurethane, vinyl chloride, polyvinyl chloride, polychloroprene andrubber.
 10. A process as in claim 1, 5 or 7 wherein the elasticcomposition layer comprises:a flexible foam layer bonded to the fabriclayer; and an elastic film bonded to the foam layer.
 11. The process asin claim 10 wherein the flexible foam layer is formed from a polymerselected from the group consisting of urethane, vinyl chloride,polyvinyl chloride, polychloroprene and rubber.
 12. A process as inclaim 1, 5 or 7 wherein the elastic composition layer includes athermoplastic film layer.
 13. A process as in claim 12 wherein thethermoplastic film layer is formed of a polymer selected from the groupconsisting of vinyl chloride, polyvinyl chloride, polyurethane,synthetic rubber, natural rubber, a mixture of natural and syntheticrubber, neoprene basis composition, and acrylic acid basis composition.14. A process as in claim 1, 5 or 7 further comprising the step ofcasting a flexible foam layer to an elastic film to form the elasticcomposition layer.
 15. A process as in claim 1, 5 or 7 wherein thefabric layer is formed of a polymer selected of the group consisting ofpolyamide, polyester, polyvinyl chloride, polyvinyl chloride copolymer,wool, cotton and combinations thereof.
 16. A process as in claim 1, 5 or7 wherein:the process further comprises the step of bonding a flexiblefoam layer to a thermoplastic film layer, and bonding the foam layer tothe fabric layer in order to form the cloth; and the heating stepincludes the step of heating the cloth to at least the softeningtemperature of the film layer.
 17. A process for molding clothcomprising the steps of:bonding a flexible foam layer to a thermoplasticfilm layer, the foam layer and film layer forming an elastic compositionlayer; bonding the foam layer to a fabric layer having a heat-fixablefiber, the cloth comprising the foam layer, film layer and fabric layer;preheating the cloth to at least the greater of the set temperature ofthe fabric layer and the softening temperature of the film layer;drawing the cloth into a heated mold, the temperature of the mold beingat least the greater of the set temperature of the fabric layer and thesoftening temperature of the film layer; heating the cloth in the moldto at least the greater of the set temperature of the fabric layer andthe softening temperature of the film layer, including the step oftransferring energy from the heated mold to the cloth; and cooling thecloth in the mold, the process heat-fixing the heat-fixable fiber of thefabric layer and the film layer to the shape of the mold.
 18. A processas in claim 2, 6 or 17 wherein the film layer is formed of a polymerselected from the group consisting of vinyl chloride, polyvinylchloride, polyurethane, synthetic rubber, natural rubber, a mixture ofnatural and synthetic rubber, neoprene-basis composition, and acrylicacid basis composition.
 19. A process as in claim 1, 5 or 17 wherein thedrawing step includes the step of creating a vacuum between the clothand the mold to thereby conform the cloth to the shape of the mold. 20.A process as in claim 1, 3, 5 or 17 further comprising the step ofpouring foam into the mold after the cooling step.
 21. A process forforming a cloth-covered item comprising the steps of:bonding a flexibleform layer to a thermoplastic film layer, the foam layer and film layerforming an elastic composition layer; bonding the foam layer to a fabriclayer having a heat-fixable fiber, the cloth comprising the foam layer,the film layer and the fabric layer; preheating the cloth to atemperature of at least the greater of the set temperature of theheat-fixable fiber and the softening temperature of the film layer;drawing the cloth into a heated mold, the temperature of the mold beingat least the greater of the set temperature of the heat-fixable fiberand the softening temperature of the film layer; heating the cloth to atleast the greater of the set temperature of the heat-fixable fiber andthe softening temperature of the film layer, including the step oftransferring energy from the heated mold to the cloth; cooling thecloth; and pouring foam into the mold, the process heat-fixing theheat-fixable fiber of the fabric layer and the film layer to the shapeof the mold and filling the back side of the molded cloth with foam.